Screen assembly and method of forming a screen assembly

ABSTRACT

A screen assembly for subsurface systems including a tubular having an outer surface. A first screen portion and a second screen portion extend about the outer surface. The second screen portion is displaced from the first screen portion by a void region. A plurality of weld plugs is mounted about the outer surface of the tubular in the void region. A centralizing ring extends about the tubular at the void region. The centralizing ring extending over each of the first screen portion and the second screen portion and is mechanically joined to the tubular through the plurality of weld plugs.

BACKGROUND

In the resource exploration and recovery industry, wellbores are formed in a formation for the purpose of discovering and exploiting formation fluids. Generally, a tubular is run into the wellbore for the purpose of delivering formation fluids to a surface system for processing, transportation and/or storage. Often times, the formation fluids pass into the tubular through a screen assembly. The screen assembly may take on various forms and could include any number of layers. The screen assembly provides passage into the tubular for desirable fluids while, at the same time, excluding undesirable fluids and/or solids.

In certain cases, the screen assembly is formed by wrapping a wire around an outside of a tubular. Wire size, wire spacing, and wire geometry may all be selected to meet various design constraints. Generally, sections of wire wrap are applied to the tubular. In between the sections of wire wrap, a gauge ring may be installed. The gauge ring is secured to the outer surface of the tubular and establishes a desired positioning or centering of the tubular in the wellbore.

Installing gauge rings is a time consuming process. A first section of wire wrap is applied to the tubular. After the first portion, the gauge ring is installed. At this point, a subsequent portion of wire wrap is installed. The need to switch between processes, e.g., wrapping wire, and wrapping gauge rings, increases the time and costs needed to form a screen assembly. Also, the need to switch processes can result in an increase in scrap if a wire spool does not have enough remaining material to form a section. The art would be open to new methods of forming screen assemblies that are less time consuming, require fewer set up steps, and result in eliminating scrap wire.

SUMMARY

Disclosed is a screen assembly for subsurface systems including a tubular having an outer surface. A first screen portion and a second screen portion extend about the outer surface. The second screen portion is displaced from the first screen portion by a void region. A plurality of weld plugs is mounted about the outer surface of the tubular in the void region. A centralizing ring extends about the tubular at the void region. The centralizing ring extending over each of the first screen portion and the second screen portion and is mechanically joined to the tubular through the plurality of weld plugs.

Also disclosed is a method of forming a screen assembly including positioning a first screen portion about an outer surface of a tubular, positioning a second screen portion about the outer surface separated from the first screen portion by a void region, mounting a plurality of weld plugs about the outer surface of the tubular at the void region, positioning a centralizing ring about the tubular over the first screen portion and the second screen portion, and securing the centralizing ring to the tubular through the plurality of weld plugs.

Further disclosed is a resource exploration and recovery system including a first system, and a second system connected to the first system through a tubular system supporting a screen assembly including a tubular having an outer surface. A first screen portion and a second screen portion extend about the outer surface. The second screen portion is displaced from the first screen portion by a void region. A plurality of weld plugs is mounted about the outer surface of the tubular in the void region. A centralizing ring extends about the tubular at the void region. The centralizing ring extends over each of the first screen portion and the second screen portion and is mechanically joined to the tubular through the plurality of weld plugs.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 depicts a resource exploration and recover system including a screen assembly, in accordance with an aspect of an exemplary embodiment;

FIG. 2 depicts the screen assembly of FIG. 1, in accordance with an aspect of an exemplary embodiment;

FIG. 3 depicts screen wire wrapped around a tubular during a process of forming a screen assembly, in accordance with an aspect of an exemplary embodiment;

FIG. 4 depicts a centralizing ring mounted to the tubular about the wire during a process of forming a screen assembly, in accordance with an aspect of an exemplary embodiment;

FIG. 5 depicts a centralizing ring and weld plug, in accordance with an aspect of an exemplary embodiment;

FIG. 6 depicts centralizing ring, in accordance with an aspect of an exemplary embodiment;

FIG. 7 depicts a weld plug joining a centralizing ring to a tubular, in accordance with an exemplary embodiment;

FIG. 8 depicts a centralizing ring, in accordance with another aspect of an exemplary embodiment;

FIG. 9 depicts a weld plug, in accordance with another aspect of an exemplary embodiment; and

FIG. 10 depicts a centralizing ring including centralizing blades, in accordance with an aspect of an exemplary embodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

A resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at 10, in FIG. 1. Resource exploration and recovery system 10 should be understood to include well drilling operations, completions, resource extraction and recovery, CO₂ sequestration, and the like. Resource exploration and recovery system 10 may include a first system 14 which, in some environments, may take the form of a surface system 16 operatively and fluidically connected to a second system 18 which, in some environments, may take the form of a subsurface system.

First system 14 may include a control system 23 that may provide power to, monitor, communicate with, and/or activate one or more downhole operations as will be discussed herein. Surface system 16 may include additional systems such as pumps, fluid storage systems, cranes and the like (not shown). Second system 18 may include a tubular string 30 that extends into a wellbore 34 formed in a formation 36. Tubular string 30 may be formed by a series of interconnected discrete tubulars or by a single tubular that could take the form of coiled tubing. Wellbore 34 includes an annular wall 38 defined by a casing tubular 40. An amount of cement 42 may be arranged between casing tubular 40 and a surface 44 of formation 36. Cement 42 may establish a selected position of casing tubular 40 in wellbore 34.

In an embodiment, shown in FIG. 2 and with continued reference to FIG. 1, a screen assembly 60 is supported by a tubular 62 connected to tubular string 30 via a coupling 63. Screen assembly 60 includes a first screen portion 64 that may be defined by a first plurality of wire wraps 65, and a second screen portion 66 that may be defined by a second plurality of wire wraps 67. First screen portion 64 and second screen portion 66 may be applied tubular 62. In an embodiment, tubular 62 may be formed by a plurality of ribs, one of which is shown at 68. First and second pluralities of wire wraps 65 and 67 may be defined by a continuous wire 70. Of course, it should be understood that wire wraps 64 may be formed by splicing together two or more sections of wire. It should also be understood that a cross-sectional geometry of continuous wire 68 (or wire sections) may vary. A plurality of centralizing rings 72 are mounted to tubular string 30 about wire wraps 64 through a plurality of weld plugs. Centralizing ring 72 establishes desired spacing between wire wraps 64 and annular wall 38 of casing tubular 40.

Referring to FIGS. 3-7, first screen portion 64 is spaced from second screen portion 66 by a void region, e.g., a section of outer surface substantially devoid of wire, it should be understood, however, that while described as being substantially devoid of wire, one or more wire wraps may pass from first screen portion 64 to second screen portion 66 across void region 90. First screen portion 64 may be supported by a first end ring 92 arranged at an uphole end (not separately labeled) of screen assembly 60 and a second screen portion 65 may be supported by a second end ring 94 arranged at a downhole end (also not separately labeled) of screen assembly 60.

In an embodiment, centralizing rings 72 extend about screen assembly 60 at void regions 90. Centralizing rings 72 include a first end 104 and an opposing second end 105 that are separated by an outer surface portion 108 and an inner surface portion 110. A discontinuity 113 is defined between first end 104 and second end 105. In an embodiment, first end 104 may include a first angled surface (not separately labeled) and second end 105 may include a second angled surface (also not separately labeled) that oppose one another at discontinuity 113. In this manner, centralizing ring 72 may define a skive cut ring (not separately labeled). The particular geometry of first and second end 104 and 105 may vary.

In an embodiment, centralizing rings 72 include a plurality of openings, one of which is indicated at 120. Each of the plurality of openings 120 extend from inner surface portion 110 through outer surface portion 108 and are sized to receive corresponding ones of the plurality of weld plugs 78. In an embodiment, each of the plurality of weld plugs 78 includes a body 130 having an outer surface section 132 and an inner surface section 133 defining an annulus. Body 130 also includes a first axial end 137 and an opposing second axial end 138.

In an embodiment, plurality of weld plugs 78 may be secured in each of the plurality of openings 120 with first axial end 137 projecting proudly of outer surface portion 108 as shown in FIG. 5. Of course, first axial end 137 may also be flush with or recessed relative to outer surface portion 108. Second axial end 138 is secured to outer surface 66 at void region 90 such that inner surface portion 110 is not connected to first screen portion 64 and second screen portion 66.

Reference will now be made to FIG. 8 in describing a centralizing ring 144 in accordance with another exemplary aspect. Centralizing ring 144 includes a first end 146 and an opposing second end 147 that are separated by an outer surface portion 149 and an inner surface portion 150. A discontinuity 156 is defined between first end 146 and second end 147. In an embodiment, first end 146 may include a first angled surface (not separately labeled) and second end 147 may include a second angled surface (also not separately labeled) that oppose one another at discontinuity 156. In this manner, centralizing ring 144 may define a skive cut ring (not separately labeled). The particular geometry of first and second end 146 and 147 may vary.

In an embodiment, centralizing rings 144 include a plurality of openings, one of which is indicated at 163. Each of the plurality of openings 163 extend from inner surface portion 150 through outer surface portion 149. Each of the plurality of openings 163 are internally threaded, e.g., include a plurality of internal threads 165 and are sized to receive corresponding ones of a plurality of weld plugs 170 such as Shown in FIG. 9. In an embodiment, each of the plurality of weld plugs 170 includes a body 173 having an outer surface section 175 and an inner surface section 176 defining an annulus. Body 173 also includes a first axial end 180 and an opposing second axial end 182. Outer surface section 175 is externally threaded, e.g., includes a plurality of threads 183 that engage with the plurality of threads 165 on centralizing ring 144.

In an embodiment, plurality of weld plugs 170 may be secured in each of the plurality of opening 163 by engaging threads 183 with threads 165 such that first axial end 180 projecting proudly of outer surface portion 175. Of course, first axial end 180 may also be flush with or recessed relative to outer surface portion 175. Second axial end 182 is secured to outer surface 66 at void region 90 such that inner surface portion 176 is not connected to either first screen portion 64 or second screen portion 66.

FIG. 10 depicts a centralizing ring 200 in accordance with another aspect of an exemplary embodiment. Centralizing ring 200 includes a first end 214 and an opposing second end 215 that are separated by an outer surface portion 218 and an inner surface portion (not separately labeled). A discontinuity 220 is defined between first end 214 and second end 215. In an embodiment, first end 214 may include a first angled surface (not separately labeled) and second end 215 may include a second angled surface (also not separately labeled) that oppose one another at discontinuity 220. In this manner, centralizing ring 200 may define a skive cut ring (not separately labeled). In the embodiment shown, centralizing ring 200 may include a plurality of centralizing blades, one of which is shown at 228 that project radially outwardly of outer surface portion 218. Centralizing blades 228 establish a desired spacing between screen assembly 60 and annular wall 38.

At this point, it should be understood that the exemplary embodiments describe a screen assembly in which centralizing rings are secured to an outer surface of a tubular while maintaining a disconnect relative to a screen surface. While the screen surface is shown as being formed from screen wire, the screen surface may take on various forms including metal mesh screens, multi-layer screens and the like. In this manner, damage to the screen wire may be avoided if the centralizing rings become stuck in a wellbore. Further, by maintaining a spacing between the screen wraps and the centralizing ring, available production surfaces are increased over prior art screens in which centralizing rings block off portions of a tubular. Finally, while shown in connection with a screen assembly, the centralizing rings described herein may be employed to connect sleeves.

Set forth below are some embodiments of the forgoing disclosure:

Embodiment 1

A screen assembly for subsurface systems comprising: a tubular including an outer surface; a first screen portion and a second screen portion extend about the outer surface, the second screen portion being displaced from the first screen portion by a void region; a plurality of weld plugs mounted about the outer surface of the tubular in the void region; and a centralizing ring extending about the tubular at the void region, the centralizing ring extending over each of the first screen portion and the second screen portion and being mechanically joined to the tubular through the plurality of weld plugs.

Embodiment 2

The screen assembly according to any prior embodiment, wherein the centralizing ring is mounted to the tubular without being connected to the first screen portion and the second screen portion.

Embodiment 3

The screen assembly according to any prior embodiment, wherein the centralizing ring includes a plurality of openings receptive of corresponding ones of the plurality of weld plugs, the plurality of weld plugs being joined to the centralizing ring at corresponding ones of the plurality of openings.

Embodiment 4

The screen assembly according to any prior embodiment, wherein each of the plurality of openings comprises threaded openings, and each of the plurality of weld plugs include external threads that engage with the threaded openings.

Embodiment 5

The screen assembly according to any prior embodiment, wherein the centralizing ring includes a discontinuity.

Embodiment 6

The screen assembly according to any prior embodiment, wherein the discontinuity defines a skive cut in the centralizing ring.

Embodiment 7

The screen assembly according any prior embodiment, wherein the first screen portion is defined by a first plurality of wire wraps and the second screen portion is defined by a second plurality of wire wraps.

Embodiment 8

The screen assembly according to any prior embodiment, wherein first plurality of wire wraps and the second plurality of wire wraps are defined by a continuous wire.

Embodiment 9

The screen assembly according any prior embodiment, wherein the centralizing ring includes an outer surface and a plurality of centralizing blades projecting radially outwardly of the outer surface.

Embodiment 10

The screen assembly according to any prior embodiment, wherein the centralizing ring includes a plurality of radially outwardly projecting centralizing blades.

Embodiment 11

A method of forming a screen assembly comprising: positioning a first screen portion about an outer surface of a tubular; positioning a second screen portion about the outer surface separated from the first screen portion by a void region; mounting a plurality of weld plugs about the outer surface of the tubular at the void region; positioning a centralizing ring about the tubular over the first screen portion and the second screen portion; and securing the centralizing ring to the tubular through the plurality of weld plugs.

Embodiment 12

The method of any prior embodiment, wherein positioning the first screen portion includes wrapping a first plurality of wire wraps about the tubular and positing the second screen portion includes wrapping a second plurality of wire wraps about the tubular.

Embodiment 13

The method of any prior embodiment, wherein wrapping the first plurality of wire wraps and the second plurality of wire wraps includes wrapping a continuous wire about the outer surface.

Embodiment 14

The method of any prior embodiment, further comprising: securing the centralizing ring to the plurality of weld plugs by engaging external threads on each of the plurality of weld plugs with internal threads formed in corresponding openings of the centralizing ring.

Embodiment 15

The method of any prior embodiment, wherein positioning the centralizing ring about the tubular aligning a first angled surface on a first end of the centralizing ring with an angled surface on a second, opposing end of the centralizing ring.

Embodiment 16

A resource exploration and recovery system comprising: a first system; a second system connected to the first system through a tubular system supporting a screen assembly comprising: a tubular including an outer surface; a first screen portion and a second screen portion extend about the outer surface, the second screen portion being displaced from the first screen portion by a void region; a plurality of weld plugs mounted about the outer surface of the tubular in the void region; and a centralizing ring extending about the tubular at the void region, the centralizing ring extending over each of the first screen portion and the second screen portion and being mechanically joined to the tubular through the plurality of weld plugs.

Embodiment 17

The resource exploration and recovery system according to any prior embodiment, wherein the centralizing ring is mounted to the tubular without being connected to the first screen portion and the second screen portion.

Embodiment 18

The resource exploration and recovery system according to any prior embodiment, wherein the centralizing ring includes a plurality of openings receptive of corresponding ones of the plurality of weld plugs, the plurality of weld plugs being joined to the centralizing ring at corresponding ones of the plurality of openings.

Embodiment 19

The resource exploration and recovery system according to any prior embodiment, wherein each of the plurality of openings comprises threaded openings, and each of the plurality of weld plugs include external threads that engage with the threaded openings.

Embodiment 20

The resource exploration and recovery system according to any prior embodiment, wherein first screen portion is defined by a first plurality of wire wraps and the second screen portion is defined by a second plurality of wire wraps.

Embodiment 21

The resource exploration and recovery system according to any prior embodiment, wherein the first plurality of wire wraps and the second plurality of wire wraps are defined by a continuous wire.

Embodiment 22

The resource exploration and recovery system according to any prior embodiment, wherein the centralizing ring includes a plurality of radially outwardly projecting centralizing blades.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

The terms “about” and “substantially” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” can include a range of ±8% or 5%, or 2% of a given value.

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. 

What is claimed is:
 1. A screen assembly for subsurface systems comprising: a tubular including an outer surface; a first screen portion and a second screen portion extend about the outer surface, the second screen portion being displaced from the first screen portion by a void region; a plurality of weld plugs mounted about the outer surface of the tubular in the void region; and a centralizing ring extending about the tubular at the void region, the centralizing ring extending over each of the first screen portion and the second screen portion and being mechanically joined to the tubular through the plurality of weld plugs.
 2. The screen assembly according to claim 1, wherein the centralizing ring is mounted to the tubular without being connected to the first screen portion and the second screen portion.
 3. The screen assembly according to claim 1, wherein the centralizing ring includes a plurality of openings receptive of corresponding ones of the plurality of weld plugs, the plurality of weld plugs being joined to the centralizing ring at corresponding ones of the plurality of openings.
 4. The screen assembly according to claim 3, wherein each of the plurality of openings comprises threaded openings, and each of the plurality of weld plugs include external threads that engage with the threaded openings.
 5. The screen assembly according to claim 1, wherein the centralizing ring includes a discontinuity.
 6. The screen assembly according to claim 5, wherein the discontinuity defines a skive cut in the centralizing ring.
 7. The screen assembly according to claim 1, wherein the first screen portion is defined by a first plurality of wire wraps and the second screen portion is defined by a second plurality of wire wraps.
 8. The screen assembly according to claim 7, wherein first plurality of wire wraps and the second plurality of wire wraps are defined by a continuous wire.
 9. The screen assembly according to claim 1, wherein the centralizing ring includes an outer surface and a plurality of centralizing blades projecting radially outwardly of the outer surface.
 10. The screen assembly according to claim 1, wherein the centralizing ring includes a plurality of radially outwardly projecting centralizing blades.
 11. A method of forming a screen assembly comprising: positioning a first screen portion about an outer surface of a tubular; positioning a second screen portion about the outer surface separated from the first screen portion by a void region; mounting a plurality of weld plugs about the outer surface of the tubular at the void region; positioning a centralizing ring about the tubular over the first screen portion and the second screen portion; and securing the centralizing ring to the tubular through the plurality of weld plugs.
 12. The method of claim 11, wherein positioning the first screen portion includes wrapping a first plurality of wire wraps about the tubular and positing the second screen portion includes wrapping a second plurality of wire wraps about the tubular.
 13. The method of claim 12, wherein wrapping the first plurality of wire wraps and the second plurality of wire wraps includes wrapping a continuous wire about the outer surface.
 14. The method of claim 11, further comprising: securing the centralizing ring to the plurality of weld plugs by engaging external threads on each of the plurality of weld plugs with internal threads formed in corresponding openings of the centralizing ring.
 15. The method of claim 11, wherein positioning the centralizing ring about the tubular aligning a first angled surface on a first end of the centralizing ring with an angled surface on a second, opposing end of the centralizing ring.
 16. A resource exploration and recovery system comprising: a first system; a second system connected to the first system through a tubular system supporting a screen assembly comprising: a tubular including an outer surface; a first screen portion and a second screen portion extend about the outer surface, the second screen portion being displaced from the first screen portion by a void region; a plurality of weld plugs mounted about the outer surface of the tubular in the void region; and a centralizing ring extending about the tubular at the void region, the centralizing ring extending over each of the first screen portion and the second screen portion and being mechanically joined to the tubular through the plurality of weld plugs.
 17. The resource exploration and recovery system according to claim 16, wherein the centralizing ring is mounted to the tubular without being connected to the first screen portion and the second screen portion.
 18. The resource exploration and recovery system according to claim 16, wherein the centralizing ring includes a plurality of openings receptive of corresponding ones of the plurality of weld plugs, the plurality of weld plugs being joined to the centralizing ring at corresponding ones of the plurality of openings.
 19. The resource exploration and recovery system according to claim 18, wherein each of the plurality of openings comprises threaded openings, and each of the plurality of weld plugs include external threads that engage with the threaded openings.
 20. The resource exploration and recovery system according to claim 16, wherein first screen portion is defined by a first plurality of wire wraps and the second screen portion is defined by a second plurality of wire wraps.
 21. The resource exploration and recovery system according to claim 20, wherein the first plurality of wire wraps and the second plurality of wire wraps are defined by a continuous wire.
 22. The resource exploration and recovery system according to claim 16, wherein the centralizing ring includes a plurality of radially outwardly projecting centralizing blades. 